Multiple heater thermal switch



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` ATTORNEY Patented Jan. 21, 1947 UNITED STATES PATENT OFFICE 2,414,531 MULTIPLE HEATER THERMAL SWITCH Francis J. Johns, Pittsburgh, Pa., assignor to Westinghouse Electric- Corporation,

burgh, Pa.,

Original application Ma 338,123, now Patent N East Pittsa corporation of Pennsylvania y 31, 1940, Serial No. o. 2,338,5

15, January 4,

1944. Divided and this application April 20, 1943, Serial No. 483,742

(cl. o-122) 8 Claims.

alternating current motors.

'Ihis application is a division of my copending application Serial No. 338,123, led May 31, 1940, Patent No. 2,338,515, issued January 4, 1944, and assigned to Westinghouse Electric & Manufacturing Company.

The use of .thermostats in the primary circuit of a, motor, or the like, as thermal protection for.

motor during the-normal operation thereof. In other words, a protective thermostat located in the primary circuit cannot, of itself, adequately protect the rotor lunder abnormally heavyfor stalled conditions. f

In addition, the use olr a. thermal protective device positioned within the rotor so as to be responsive vto the heat thereof is well known. However, in all such cases the device cannot be made to operate within the safe limits of the rotor and at the same time permit the rotor to accelerate under severe accelerating conditions. In other words, such thermal under heavy load conditions regardless of the protection ,afforded under 4locked rotor conditions.

In all cases the protective devices have thus had' to be set at an arbitrary value without due regard to the complete thermal protection of the motor.

To overcome these serious disadvantages and to adequately protect the motor under all conditions, I propose to incorporate a thermal protective device with the rotor, which is inversely responsive to the speed of such rotor. Such a device equally protects the rotor under both stalled and heavy or abnormal accelerating` conditions.

One object of my invention is to provide a thermal switch capable of being mounted within the air passage of a motor having a heater for operating such swltchelectrically associated with the rotor for supplying heat to the switch inversely in response to the speed of the rotor and adapted to be cooled by air directly in -response to the rotating speed of the rotor.

Another object of my invention is to provide a thermal switch having a thermally responsive member, and a heater thermally associated therewith, with a baille positioned adjacent the heater to direct the passage of air thereabouts to cool the heater in direct response to the passage of such air. I

Other objects of my invention will either be pointed out specically in the course of the fola device embodying my invention, or will be apparent from such description. f

In the accompanying drawing:

Figures 1 and 2 are front and side views, re-

' spectively, of a thermostatic switch embodying thereof,

from any other suitable insulating material. 'Ihe cup-shaped housing or casing l2 has a centrally located apparatus-receiving space 26, a base portion 3U, a cylindrical or sleeve-like portion 28 and a peripheral internally shouldered ange 3|. The base 3 0 and cylindrical portions 3| and 2B, respectively, are, in this instance, formed as an integral member. Suitable ear or anged portions 32 are integrally formed with the base 30 substantially diametrically opposite to each other to aiord means for rigidly attaching the therknown manner.

. ing such heater.

agresor l d mostat le to the motcrt, as hereinafter deB scribed.,

The binietallic disc it is, in this instance, a disc of a well-known type which is rigidly ats tached to the base tti of housing iti by means of a suitable opstanding post te. The bimetaliio member it is rigidly attached to the base t@ by means oi such post so as to iler: from the concave or operative position (see Fig. 3) to a conm ver: or inoperative position (see Fig. in a well tioned within the hollow portion 2b of the supporting structure l substantially coaxially therewith so as to operate wholly within such hollow portion, as hereinafter described. A plu= rality of movable contacts to are rigidly attached to such member ld so as to cooperate with suitable stationary contact members te.

Suitable elongated or slot-like apertures te (see Figs. 2 and 3) are located within the up= standing cylindrical portion 2d of the housing or supporting structure l2 to permit the passage of air therethrough as hereinafter described. Such apertures are positioned substantially in line with the bimetaliic member id or intermediate such'member and the heating element it to permit the air passing over and about such ele= ment to pass therethrough, as hereinafter described.

The terminal and stationary contact members t@ are positioned upon and pass through the base portion t@ or" casing l2 to cooperate with the contacts do rigidly attached to the bimetallic member it. The contact structures ttl comprise a button-like contact member te located within the hollow portion it and elongated terminal portions di and ilu which pass through the base portion 3Q oi housing i2. The contact members so in cooperation with member lo thus provide means for conducting electric power through the thermostat lo. e

The heating element lo is mounted on the outer section of the hollow portion 2e of casing l2 and is positioned in such a manner that the blmetallic member lit may flex from an operetive to en inoperative position without contact- Such heating element i@ may be formed of any suitable electrical resistance material having any desired cross-sectional conlguration. However, it is preferred that such element be formed of ordinary circular wire for low current usages and of ribbon-like material for high current usages. The heater l is, in this instance, a flat circular ribbon-like member, the ends of which pass outwardly through the upstanding portion 28 of casing l2 to afford means for making connection with such heater.

The ribbon-like heater l is looped into substantially an annulus, and is positioned substantially coaxially and parallel with the bimetallic member l5 so as to be in normal thermal communication therewith.

The heating element i8 is an elongated resistance member which is disposed around the up-- standingl post 3ft intermediate the bimetallic member it and base 3o in a well-known man ner. One end of the heater I8 is rigidly attached to one of the stationary contact members .38, while the other end of such heater I8 passes through base 3b and functions as a terminal 42 for the switch structure it. The heating ele=` ment it, like element I6. is in thermal communi-I cation with the bimetallic member I4, whereby such elements are adapted to control the movements of the bimetallic member I4 in response'to Bimetalllo member ll is posithe passage of current through the elements as hereinafter described.

The two heating elements lo and le are adapted to act independently upon the bimetallic member lli. The element le is preierably associateo'. with the rotor o a motor and is adapted to receive the current owing therethrough, while the element l is connected in the circuit with the main winding of the motor in a well-known manner.

rlhe substantially cup-shaped air heme strue-l ture or cover 2t, preferably formed of insulating material, comprises a centrally located, prei-erably integral, hnoblllse or semi-spherically shaped baing portion and an exterlorly lo cated sleeve-like portion fit, and is adapted to nt against the internally shouldered outer end or the cylindrical portion is of structure it and be secured therein in any suitable manner. The

semi-spherically shaped baie portion dit is prei erably formed with and rigidly lattached to the sleeve portion e@ by means of suitably extending members or armsdd, so as to be positioned sub= stantially in the center or the structure. The portion dd is thus Asubstantially coaxial with the element l and bimetallic disc ift. Semi-circo lar or arcuate apertures are thus formed about the portion it to pet the passage or" air therethrough. Such baiting portion l is thus adapted to direct the passage of air passing through the thermostat ill, as hereinafter described.

The members or arms de are as small as prac tically possible to adequately support the snoblilte semi-sphercally shaped battling portion @it so as to not seriously impede the travel of air through the thermostatic structure, as hereinafter described.

The air baiiiestructure 2e is thus adapted to direct or lt the passage of airthrough the thermostat so that substantially all of such air will engage the at ribbon-like radiant element it. Such air, after engaging the element ld, passes out through the apertures te inthe side wall 23 of the thermostat housing l2. However, the air passing through the thermostatic switch it, due to the presence of bao portion et and or radiant element l, does not encounter the bi metallic member le so asl to seriously alter the operations thereof, as hereinafter described.

The thermostatic switch l@ is rigidly attached to the motor 22, a portion of which is merely shown herein, by means oi suitable bolts 5t which pass through the protrudinglor flange portions 32 of casing l2. The thermostat l@ is positioned within an air passage of the motor 22, prefer ably between the frame and stator portions thereof. However, such thermostat may be mounted upon the motor in any other desired position so as to be in the path of air passing therethrough. A portion of the air passing through the motor is thus adapted to pass through the thermostat. As indicated by the arrows, this air enters the thermostat through the semi-circular slots 6B in the base of sleeve et, passes about the radiant element IS, and out the plurality of slots 3G in the sleeve portion 2S of base l2. The presence of baille structure 2D and radiant element I6 pre= vents a large portion of such air from engaging the bimetallic member- I8. However, the passage of air through the thermostat always tends to counteract, to a greater or lesser degree, the heating eiect of heating element l on the bimetallic member ld and retard its action, as hereinafter described.-

phase motor having a main field Vand 40', from the power supply -ingly cools the element I6 switch I is electrically associated with the mo-I tor 22, as well asbeing mechanically attached thereto, in a manner -as illustrated in the schematic wiring diagram of-.Fig 4. The motor 22 constitutes, in this instance, a so-called repulsion induction motor or, in other w'ords,'a` singlewinding 56 and a wound' rotor 24 with a commutator thereon and However, should :there be an abnormally heavy load associated with the rotor l24 which prevents short-circuiting brushes 25 operatively associated with a suitable centrifugal device 54 which is adapted to raise the brushes 25 when the rotor 24 attains a predetermined operative speed, in a well-known manner.`

The nat ribbon-like heating element I6 is connected in series with the rotor 24 and the centrifugal starting device 54 so as to permit the rotor current to pass therethrough. The heating element I8 is connected in series with the bimetallic member I4 and the primary winding 56 of the motor 22, in a well-known manner. The bi- .metallic member I4 being in thermal communication with such elements I6 and I8 receives heat therefrom 'in direct response to the current passing through the rotor 24 and the--primary winding 56. Should the total heat delivered to the bimetallic member I4 beabove a predetermined value, such member will flex to an open position, Fig. 7, disengaging so as to disconnect the main Winding 56 Assuming the motor 22 is initially disconnected from the power supply and is then connected to such power supply by means of a suitable switch 58, the rotor 24 will startto rotate with the brushes 25'in aloWeror engaging position in a. well-known manner. The current passing through the rotor 24 will then pass through the heater I6; However, such current will decrease in value with the increase in rotative speed of the rotor 24. Therefore, assumingthat there is a normal loadon such motor,l the rotor will gradually increase to a predetermined rotative speed, at which time the centrifugal mechanism 54 will raisethe brushes 25 and disconnect the heater I6 fromsuch rotor. The motor will then run as y a regular single-phase, squirrel-cage motor, in a well-known manner.

The current .flowing through the rotor and heating element is thus responsive to the rotative speed thereof, being a maximum at the time of starting and a minimum just prior to the action of the centrifugal mechanism 54. In other words, theheat produced by heating element I6 varies inversely with the rotative speed of the rotor.

As the rotor 24 increases in speed, the quan-` tity and velocity of air passing between the stator laminations and the frame ofthe motor 22 (see arrows in Fig. 3) increases. A portion of this air is directed through the thermostat I0 by means of the bailling structure 20. This, in turn, increasincrease in rotative speed of the rotor 24.

It, therefore, follows that, as the rotor 24 increases in speed, the heating effect of element I6 upon bimetallic member I4 decreases because of two reasons, namely, thedecrease in current passing through the rotor 24 and theincreasing quantity of cooling air passing through the baille and about such heater. Therefore, as the rotorspeed increases, the action of this cooling air supplements the action of the heating element I6 with respect'to its effect on bimetallic element I4, as each Aof these actions tends to keep down the actual heating of the bimetallic element.

the cooperating contacts 39' in direct ratio to the tively slow rate'.

heater I6 being directly responsive to the value y quickly as with which passes through the baille 20 the rotation thereof to the power supply, such rotor will be proportionately abnormally large. The heat produced by element I6 will thus, likewise, be abnormally large. Accordingly, bimetallic .member I4, cation with the heater position in response to such heat within a period of say three tofour seconds. therefore, be disconnected from the power supply so as to adequately protect such rotor and 4its associated commutator as a result of this stalled" or locked-rotor" condition of ,the motor.

Assuming that the load associated with the rotor 24 is above a predetermined safe value but is of suchvalue as to permit the rotor 24 to rotate at a low speed, the current passing through the rotor 24 and heater I6 will accordingly decrease from an initial relatively. high value at a rela- The heat produced by such as the motor 22 is connected of current flowing therethrough will, therefore, increase invalue at a relatively rapid rate. However, the heat produced by such heater will not directly act vupon the bimetallic member` I4 as the shorted or locked rotor condition hereinabove described, inasmuch as there will be a passage of cooling. air through the motor vindirect ratio to the rotative speed of such rotor about the proportion that with heater I6, cooling'the heater in direct to such speed It. therefore, follows the abnormal heavy load and slow speed men- 4 tioned; the heater I6 will heat at a relatively rapid rate and will be cooled much slower than it will when operating in a normal manner. The bimetallic member say, 6 to 8 seconds, depending upon the rotative speed and acceleration of such rotor.

It follows, therefore, that with the heater I6 being electrically associated with the rotor 24 so as to receive current therefrom inversely in magnitude with respect to the rotation of such rotor, and with such heater I6 being adapted to be contacted by air passing through the motor in direct proportion to the rotative speed of such rotor, the combined reaction of these two factors tends to vary theeifective heating characteristics of such heater I6, which variation, in turn, is thermally conducted to the bimetallic member I4 so as to operate such member in response to the varying starting conditions of the motor.

Ii it be desired, the thermostat Ill may be associated with a motor 22a in a modified manner (see schematic wiring diagram of Fig. 5).' The motor 22a illustrated in Fig. 5 is substantially the same as motor 22 illustrated in Fig. 4 and hereinabove described. However, the heating element I6 is, in this instance, directly connected to the power supply 60 through the centrifugal mechanism 54 rather than in series with the rotor 24. The operation of the rotor 24 and the protective device I 0 is substantially as hereinabove described and as follows.

When'there is 'a locked rotor element I6 to remain connected to the power supply while the rotor remains stationary. Accordingly, the heat produced by heating element I6 directly acts uponthe bimetallic member I4. This heat, which is not being conducted away by the passage of air through the thermostat, in

the current flowing through4 being in thermal communi.

I6, will flex to its open The motor 22 will,

I4 will thus operate in from,l

' condition, the. centrifugal mechanism 54 permits the heating primary winding functioning by itselfv forl a atrapar conjunction with that supplied bythe heating element i8, causes the bimetallicmember id to quickly disengage the motor from the power supply within, say,I 3 to e seconds,

Further. when there .is an abnormally heavy' c rotativev speed of rotor 2d.

Further, if the load applied to motor 22 be ci a normal or safe value-the acceleration of rotor it will cause the speed to increase to such a value as toproduce a larger quantityof air, so as m cool or` convey the heat developed by .heating element i3 away from the element at such a rate asto prevent the bimetallic-member id from increasing in temperature above the predetermined operating value thereof. Then as the rotative speed oi the rotor reaches a predetermined set value, the centrifugal mechanism will operate so as to disengage the starting brushes associated with the rotor and to disconnect the heating element it lfrom the power supply. The motor will then operate in a, manner` well known, with the heating element i8 directly in series with Ithe Wellhnown thermal protective'purpose. v .I

ii it be desired, theth'ermal protective device iii may be operatively associated 4w'it1i1, s ay a splitphase or squirrel-cage .motor functioning as a 'capacitor motor 22h, or thelike, (see the schematic diagram of Fig. 6) ln this'instance, the

heating element i6 is connected directly in vseries with the starting coil di of motor 221i.-v Such thermal protective device functions substantially as hereinabove described, namely through the cooperation of the current passing through the starting winding 51 and the quantity of air passing through the motor. -in this instance, under locked load conditions, the current passing through the starting winding 51, element i6 and centrifugal mechanism 5E will be abnormally large and at the same time there willbe no-air passing through the motor. Accordingly, the bimetallic member id will be actuated by means of the heat produced within the heating elements it and ld within substantially 3v to Li seconds.

However, should the low rotative velocity, will tend to cool the heater it, this cooling rate being directly responsive to the rotative speed oi the rotor. It follows that when such rotor does not accelerate to a predetermined speed, the birnetallic member will be suiliciently heated to be actuated and disengage the motor 22h from the power supply. However, should the motor accelerate to a predetermined desired speed, it iollows that the velocity o f air passing through the motor will be of such a value as to cool the heating element I6 at such a rate as to permit the bimetallic member it to remain in the closed or rotor Nb have a relatively engaged position until the centrifugal device 5B is actuated. After the actuation of such device, the heating element i6 has no eilect upon the himetallic member It as hereinabove described.

Accordingly,

a. well-known manner and actuate the birnetallic member when the motor becomes overheated during vits running condition.

It is to be understood that the heating element it may be electrically associated with a motor 'in any other desired manner to receive current therefrom inversely with respect to the rotative speed thereof, until the rotor reaches a predetermined value of speed or until such time as the motor. y It is obvious that the heating element it as c motor shall operate as a straight single-phase sociated with the bimetallic member ld may be electrically associated with the motor iii any other desired manner; and, if desired, may'not be assol ciated with the bimetallic member it but may be associated with a second bimetallic member lo' cated at any desired point, inasmuch as heating element it has no direct bearing upon the operation of the heater it and its cooperation with the bimetallic member it. It will be appreciated that the bimetallic element it may readily be so designed as to properly operate with only heating element i6 associated therewith-or with both heatingelements it and it disposed adjacent thereto, as illustrated.

Various other modications may be made in the device embodying my invention without departing from the spirit and scope thereof, and

i desire, therefore, that only such limitations shall be placed thereon as are imposed by the prior art and the appended claims.

l claim as my invention:

i. A thermal switch comprising a supporting housing, a bimetallic member mounted within said housing, a cover for the housing having an the air produced thereby opening therein to permit the passage of air therethrough, a rst radiant heater for said member mounted intermediate the member and cover in the path of the air passage therethrough so as to be controlled by the amount and velocity of such air, and a second radiant heater mounted outside the path of the air passage so as to function independently from said air.

2. A thermal switch comprising a housing having openings therein to permitv the passage of air therethrough, a bimetallic member, a radiant heater thermally associated with said member and positioned with respect to the openings so as to be aected by the air passing therethrough, and a second radiant heater thermally associated with said bimetallic member and positioned so as to operate substantially independently of the air passing through the openings in the housing.

3. A thermal switch comprising a supporting housing having openings therein to permit the passage of air therethrough, a bimetaliic member,

a plurality of radiant heaters disposed on opposite sides of said bimetallic member, and baille means so disposed as to cause said air to aiect one only of said radiant heaters-before passing out of said housing.

4. A thermal switch comprising a supporting housing having a longitudinally extending and a laterally extending opening therein to permit the passage of air therethrough, a, bimetallic member, and a plurality of radiant heaters therefor respectively disposed near to and remote from said openings.

5. A thermal switch comprising a supporting yhousing having an entrance and an exit opening for air disposed to produce a curve in air stream,

a bimetallic member, and a plurality of radiant the heating elementitwassociatedmV Y i with the main winding will thereafter function in 9 heaters therefor respectively disposed within the curve of said air stream and remote therefrom.

6. A thermal switch comprising a supporting housing having an entrance and an exitopening for air disposed to produce a curve in air stream, a bimetallic member, and a plurality of radiant heaters therefor respectively disposed on one side of said blmetallic member within the curve of said air stream and on the other side of said bimetallic member in a pocket oi' said housing.

'1. A thermal switch comprising a supporting housing having a lateral opening near one end thereof, a bimetallic member mounted therein, a

cover for that end of the housing having anopening therein to permit the passage of air therethrough, a rst radiant heater for said bimetallic member disposed near said cover to be affected by the passage of said air, and a second l radiant heater for said bimetallic member mounted near the end of said housing remote from said lateral opening.

8. A thermal switch comprising a supporting housing having a lateral opening near one end thereof, a bimetallic member mounted therein, a cover for that end of the housing having a central cup-shaped central baie and an opening partially encirclingthe vsame to permit the passage ofair, a iirst radiant heater for said 'bimetallic member disposed in part opposite said opening in the cover in the path of air therethrough, and a second radiant heater for said bimetailio member mounted within a pocket of said housing at the end thereof remote trom said baiiie. v

. FRANCIS J. JOHNS. 

